Porous supported articles and methods of making

Abstract

Porous supported articles and methods of making are disclosed. Multicomponent polymeric fibers are introduced into a forming chamber and are infilled at least into the interior void spaces of a support web. At least some of the infilled multicomponent component fibers are self-bonded to each other to form a porous web that is embedded within the support web. The porous embedded web may contain particles that are bonded to the multicomponent fibers of the web. The optional particles in the porous embedded web may be e.g. abrasive, absorbent, etc.

What is claimed is: 
     
       1. A method of making a porous supported web, comprising:
 introducing discontinuous multicomponent polymeric fibers into a forming chamber; 
 mixing the multicomponent fibers within the forming chamber; 
 infilling the multicomponent fibers into at least some interior void spaces of a filamentary support web comprising a thickness, to form an infilled fibrous mat within at least some of the interior void spaces of the support web; and, 
 exposing the multicomponent fibers to an elevated temperature to melt-bond at least some of the multicomponent fibers to each other so that the fibrous mat is self-bonded into a porous web that is embedded within at least some of the interior void spaces of the support web;
 wherein the infilled multicomponent fibers partially fill the thickness of the filamentary support web so that the entirety of the porous embedded web is located within the thickness of the filamentary support web so that first and second major surfaces of the porous embedded web are within the interior of the filamentary support web and so that at least some of the filaments of the filamentary support web extend outwardly from the porous embedded web beyond a major surface of the porous embedded web. 
 
 
     
     
       2. The process of  claim 1  wherein the infilling of the multicomponent fibers into the interior void spaces of the support web is performed by passing the support web through or underneath the forming chamber and gravity-dropping the multicomponent fibers into the support web, and wherein the elevated temperature exposure is achieved by passing the support web with the infilled fibrous mat therein through a heating unit that is separate from the forming chamber. 
     
     
       3. The process of  claim 2  further comprising applying at least a partial vacuum to a major surface of the support web such that a pressure differential exists through the support web to assist the infilling of the multicomponent fibers into interior void spaces of the support web. 
     
     
       4. The process of  claim 1  wherein at least one of the first and second major surfaces of the porous embedded web comprises a densified surface layer. 
     
     
       5. The process of  claim 1  wherein the support web has a generally closed first major surface that comprises a plurality of flattened, coplanar filament loops, and has a generally open second major surface that is defined by portions of filaments that are distal to the first major surface of the support web, and wherein the infilling of the multicomponent fibers into the support web is performed by infilling the fibers into the generally open second major surface of the support web. 
     
     
       6. The process of  claim 1  wherein the filaments of the support web have an average diameter of at least about 200 microns. 
     
     
       7. The process of  claim 1  wherein the multicomponent fibers comprise a Denier of between about 1 and about 5. 
     
     
       8. The process of  claim 1  further comprising introducing particles into the forming chamber, mixing the particles with the multicomponent fibers, infilling the particles and multicomponent fibers into the support web, and exposing the multicomponent fibers and the particles to an elevated temperature to melt-bond at least some of the multicomponent fibers to each other and to melt-bond at least some of the particles to at least some of the multicomponent fibers to form a porous, particle-containing web that is embedded within at least some of the interior void spaces of the support web. 
     
     
       9. The process of  claim 8  wherein the particles are selected from the group consisting of abrasive particles, metal particles, detergent particles, surfactant particles, biocide particles, adsorbent particles, absorbent particles, microcapsules, and combinations thereof. 
     
     
       10. The process of  claim 9  wherein the particles are absorbent particles selected from the group consisting of chopped cellulosic sponge particles and chopped polyurethane sponge particles and mixtures thereof. 
     
     
       11. The process of  claim 1  wherein at least some of the multicomponent fibers are melt-bonded to at least some of the filaments of the support web. 
     
     
       12. The process of  claim 1  further comprising providing a binder coating applied to a major surface of, or applied into the interior of, the porous embedded web. 
     
     
       13. The process of  claim 12  wherein the binder coating comprises abrasive particles. 
     
     
       14. The process of  claim 1  further comprising introducing filling fibers into the forming chamber, mixing them with the multicomponent fibers, and infilling them into at least some of the interior void spaces of the support web. 
     
     
       15. The process of  claim 1  further comprising cutting through the thickness of the support web and the porous embedded web therein so as to separate the porous supported web into a plurality of porous supported articles. 
     
     
       16. The process of  claim 1  wherein the elevated temperature exposure comprises passing the support web and the embedded web therein through a through-air bonder. 
     
     
       17. The process of  claim 1  wherein the fibers are mixed within the forming chamber by a plurality of rotating spike rollers. 
     
     
       18. The process of  claim 1  wherein the filamentary support web exhibits a basis weight of at least about 200 grams per square meter and wherein the porous embedded web exhibits a basis weight of at most about 500 grams per square meter.